Sensor and temperature sensor capable of automatic installation

ABSTRACT

A temperature sensor includes a substantially rod-shaped guide portion  28  vertically protruding from a vertical wall  20   c  of a substrate. A harness  40  is fixed to the guide portion  28  in a contacting state by accommodating the guide portion  28  and the harness  40  in a vinyl tube  44 . Because of this configuration, a root portion of the harness  40 , which extends from the substrate  20 , is unlikely to be bent, broken or disconnected due to the rigidity of the guide portion  28.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a sensor and, particularly, to atemperature sensor preferably used for sensing the temperature of anevaporator.

Moreover, the present invention relates to a sensor adapted to be formedby fixing a cylindrical metal case for accommodating a sensing elementon a three-dimensional substrate and, particularly, to a temperaturesensor adapted to be formed by installing an installation portion formounting on an evaporator and a cylindrical metal case for accommodatinga temperature sensing element on a three-dimensional substrate in avertically standing state.

2. Description of the Related Art

In an air-conditioner for a vehicle, a temperature sensor is installedon an evaporator in order to measure the temperature of a refrigerant.The construction of the temperature sensor for an evaporator isexplained with reference to FIGS. 12A to 12D. FIG. 12A is a plan view ofan evaporator temperature sensing element 110, FIG. 12B is an elevationview from the arrow X12 b in FIG. 12A, FIG. 12C is an elevation viewfrom the arrow X12 c in FIG. 12A, and FIG. 12D is a sectional view takenalong the line X12 d –X12 d in FIG. 12C.

The evaporator temperature sensor 110 is formed as an insert moldingwith a resin, wherein an aluminum case 130 for accommodating atemperature sensing element 32 at the top end thereof and aninstallation portion 126 for mounting on an evaporator are installed ona substantially cubic substrate 120 in a standing state. Grooves 126 afor preventing withdrawal are formed on the installation portion 126. Aharness 40 connected to a signal wire 42 from the temperature sensingelement passes through a vertical wall 120 c of the substrate 120. Theevaporator temperature sensor 110 is fabricated by accommodating thetemperature sensing element 32 in the aluminum case 130, by placing thealuminum case 130 filled with filler 122 in a mold and by insert moldingwith a resin.

FIG. 13 shows a state in which the evaporator temperature sensor 110 isinstalled on an evaporator 50.

The evaporator temperature sensor 110 is installed by inserting thealuminum case 130 and the installation portion 126 into spaces betweenfins 52 of the evaporator 50.

In the patent documents 1 to 4, air-conditioners for a vehicle using anevaporator temperature sensor are disclosed.

[Patent document 1]

Japanese Unexamined Patent Publication (Kokai) No. 2002-211,233

[Patent document 2]

Japanese Unexamined Patent Publication (Kokai) No. 7-237,440

[Patent document 3]

Japanese Unexamined Patent Publication (Kokai) No. 6-48,168

[Patent document 4]

Japanese Unexamined Patent Publication (Kokai) No. 5-238,253

In the evaporator temperature sensors 110 of a prior art, however, asthe harness 40 is not fixed to the substrate 120, the root portion ofthe harness 40 at which the harness 40 comes out from the substrate 120is likely to be bent and is often broken and disconnected due tovibration during operation of a vehicle or the vibration of a compressorof an air-conditioner.

During the insert molding with a resin, however, as heat is exerted ataround 250° C., the harness 40 is required to be made of a materialhaving heat resistance higher than or equal to 250° C., and thereby, thecost of the evaporator temperature sensor is increased.

The evaporator temperature sensor may be installed on various positionsin accordance with the type of a vehicle or air-conditioner casings. Dueto this installation position, the harness is required to be long whichmakes it difficult to handle. In this configuration, during insertmolding, if the harness is long, it is troublesome to set the harnessinto a mold and easy to insert the harness into the mold. On the otherhand, in order to correspond to various installation positions, aplurality of harnesses having various lengths should be prepared, but itis difficult to combine these harnesses having various lengths togetherby insert molding. Therefore, the manufacturing process is difficult toautomatically perform and is, instead, manually performed with resultingincrease in the manufacturing cost.

On the other hand, if the harness 40 is not fixed to the substrate 120by insert molding, the root portion of the harness 40 at which theharness 40 comes out from the substrate 120 is likely to be bent and maybe broken and disconnected due to vibration during operation of avehicle or the vibration of a compressor of an air-conditioner.

In addition, if the relative position of the harness 40 with respect tothe evaporator temperature sensor 110 is not fixed, when the evaporatortemperature sensor 110 is installed on the air-conditioner case, thebend of the harness 40 must be adjusted. Due to this, there is a problemin which it is difficult to automate the installation of the evaporatortemperature sensor 110. The operation of installation is explained withreference to FIG. 13.

After the evaporator temperature sensor 110 is installed on theevaporator 50 accommodated in an air-conditioner case 60, the harness 40is settled into a groove 64, lids 62A and 62B are closed and, thereby,the installation operation is finished. During the operation, if theposition of the harness 40 is not fixed, the efficiency of the operationis lowered. Moreover, if the position of the harness 40 is not fixed,automatic assembling is difficult.

SUMMARY OF THE INVENTION

The present invention has been developed with above-mentioned problemsbeing taken into consideration, and the object thereof is to provide asensor or a temperature sensor that has a harness of which the rootportion has improved reliability.

Another object of the present invention is to provide a sensor or atemperature sensor capable of holding a cylindrical metal case thereofwithout using an insert molding.

In order to solve the above-mentioned problem, a sensor 10, according toa first aspect of the present invention, comprises: a sensing element 32which is received near a top end of a cylindrical portion 30 mounted ona substrate 20 in a standing state; and a harness 40 from the sensingelement 32 which comes out from the substrate 20; wherein a guideportion 28 extending from the substrate 20 along the harness 40 isprovided; and wherein the harness 40 comes into contact with and isfixed to the guide portion 28 by accommodating the guide portion 28 andthe harness 40 in a tube 44 which retains the harness 40.

A temperature sensor 10 according to a second aspect of the presentinvention comprises: a three-dimensional substrate 20 made of a resinand including an upper surface 20 a, a lower surface 20 b, a verticalwall 20 c and a substantially rod-shaped guide portion 28 verticallyprotruding on the vertical wall 20 c; an installation portion 26 forinstalling on a measured member 50 and vertically mounted on the uppersurface 20 a of the substrate 20 in a standing state; a cylindricalportion 30 receiving a temperature sensing element 32 near a top endthereof and vertically mounted on the upper surface 20 a of thesubstrate 20 in a standing state; a harness 40 connected to thetemperature sensing element 32 and coming out from the vertical wall 20c of the substrate 20 after passing through an inside of the cylindricalportion 30; and a tube 44 for fixing the harness 40 to the guide portion28 in a contacting state by accommodating the guide portion 28 and theharness 40.

In a sensor 10 according to the first aspect, the guide portion 28extending from the substrate 20 of the cylindrical portion 30 retaininga sensing element and along the harness 40 is provided, and the harness40 comes into contact with and is fixed to the guide portion 28 byaccommodating the guide portion 28 and the harness 40 in the tube 44.Because of this, a root portion of the harness 40 which comes out fromthe substrate 20 is unlikely to be bent due to the rigidity of the guideportion 28, and is seldom broken and disconnected. In addition, as theposition of the harness 40 with respect to the sensor can be maintainedconstant, the harness 40 never acts as an obstruction, and it ispossible to assemble the sensor 10 automatically.

In a temperature sensor 10 according to the second aspect, thesubstantially rod-shaped guide portion 28 vertically protruding on thevertical wall 20 c of the substrate 20 is provided, and the guideportion 28 and the harness 40 are accommodated in the tube 44, so thatthe harness 40 is fixed to the guide portion 28 in a contacting state.Because of this, a root portion of the harness 40 which comes out fromthe substrate 20 is unlikely to be bent due to the rigidity of the guideportion 28, and is seldom broken and disconnected. In addition, as theposition of the harness 40 with respect to the temperature sensor can bemaintained constant, the harness 40 never acts as an obstruction, and itis possible to automatically assemble the temperature sensor 10.

According to a third aspect of the present invention, it is preferablethat a rib 28 a having an outer diameter greater than the inner diameterof the tube 44 is provided on the guide portion 28. By thisconfiguration, the tube 44 is difficult to withdraw due to theresistance of the rib 28 a. As a result, the root portion of the harness40 which comes out from the substrate 20 is seldom broken anddisconnected, by fixing the harness 40 on the guide portion 28 using thetube 44.

According to a fourth aspect of the present invention, as the guideportions 28A and 28B, which are made by dividing the guide portion 28into two parts, sandwich and hold the harness, the harness 40 can befirmly fixed by the guide portion 28.

According to a fifth aspect of the present invention, as a ring-shapedgroove 24 which is provided on the vertical wall 20 c of the substrate20 is made to accommodate a front end of the tube, the tube 44 isdifficult to withdraw and, as a result, the root portion of the harness40 which comes out from the substrate 20 is seldom broken anddisconnected, by fixing the harness 40 on the guide portion 28 using thetube 44.

According to a sixth aspect of the present invention, as theinstallation portion 26, which is vertically mounted on the uppersurface of the substrate 20 in a standing state, comprises return edges26 a acting as hooks for preventing the withdrawal, the return edge 26 aengages with cooling fins of an evaporator by inserting the installationportion 26 between the cooling fins and it is possible to easily installthe temperature sensor into the cooling fins of the evaporator.

According to a seventh aspect of the present invention, a sensor 210comprising a cylindrical metal case 230 which receives an sensingelement 232 in a top end thereof and is fixed on a three-dimensionalsubstrate 220; wherein a flange portion 230 a with an outer diameterenlarged near its opening 230 c opposing to the top end of thecylindrical metal case 230 is provided, a through-hole 222 a making thetop end of the cylindrical metal case 230 insert and penetrate throughan upper surface 220 a of the substrate 220 is provided on the uppersurface 220 a of the substrate 220, a hollow portion 222 c receiving theflange portion 230 a of the cylindrical metal case 230 whichcommunicates with the through-hole 222 a is provided immediately belowthe through-hole 222 a, and hook portions 222 d protruding inside areprovided immediately below the hollow portion 222 c; and wherein the topend of the cylindrical metal case 230 is inserted through thethrough-hole 222 a of the substrate 220, the hollow portion 222 c of thesubstrate 220 receives the flange portion 230 a of the cylindrical metalcase 230, and the opening 230 c of the cylindrical metal case 230engages with the hook portions 222 d, so that the cylindrical metal case230 is fixed to the substrate 220.

According to an eighth aspect of the present invention, a temperaturesensor comprises: a cylindrical metal case 230 receiving a temperaturesensing element 232 in a top end thereof; and an installation portionfor installing the temperature sensor to a measured member which ismounted on a three-dimensional substrate 220 in a vertically standingstate; wherein a flange portion 230 a with an outer diameter enlargednear its opening 230 c opposing to the top end of the cylindrical metalcase 30 is provided, a first through-hole 222 a allowing the top end ofthe cylindrical metal case 230 to be vertically inserted and topenetrate through an upper surface 220 a of the substrate 220 isprovided on the upper surface 220 a of the substrate 220, a hollowportion 222 c receiving the flange portion 230 a of the cylindricalmetal case 230 which communicates with the first through-hole 222 a isprovided immediately below the first through-hole 222 a, and a secondthrough-hole 222 e for inserting the cylindrical metal case 230therethrough and hook portions 222 d protruding to the inside of thesecond through-hole 222 e are provided immediately below the hollowportion 222 c; and wherein the top end of the cylindrical metal case 230is inserted through the first through-hole 222 a of the substrate 220,the hollow portion 222 c of the substrate 220 receives the flangeportion 230 a of the cylindrical metal case 230, and the opening 230 cof the cylindrical metal case 230 engages with the hook portions 222 d,so that the cylindrical metal case 230 is fixed to the substrate 220.

In the seventh aspect of the present invention, the flange portion 230with an outer diameter enlarged near its opening 230 c opposing to thetop end of the cylindrical metal case 230 is provided. On the otherhand, the through-hole 222 a allowing the cylindrical metal case 230 tobe inserted and to penetrate through the upper surface 220 a of thethree-dimensional substrate 220 is provided on the upper surface 220 aof the substrate 220, the hollow portion 222 c receiving the flangeportion 230 a of the cylindrical metal case 230 which communicates withthe through-hole 222 a is provided immediately below the through-hole222 a, and the hook portions 222 d protruding inside are providedimmediately below the hollow portion 222 c. The top end of thecylindrical metal case 230 is inserted through the through-hole 222 a ofthe substrate 220, the hollow portion 222 c of the substrate 220receives the flange portion 230 a of the cylindrical metal case 230, andthe opening 230 c of the cylindrical metal case 230 engages with thehook portions 222 d, so that the cylindrical metal case 230 is fixed tothe substrate 220. In other words, the cylindrical metal case 30 can befixed by inserting it into the through-hole 222 a of the substrate 220,so that the cylindrical metal case 230 can be fixed without performingan insert molding. Moreover, as the insert molding is not performed, theharness is not required to have heat resistance for withstanding theinsert molding and it becomes possible to use a cheap harness which canbe used in many applications.

In the temperature sensor 10 according to the eighth aspect, the flangeportion 230 a with an outer diameter enlarged near its opening 230 copposing to the top end of the cylindrical metal case 30 is provided. Onthe other hand, the first through-hole 222 a allowing the cylindricalmetal case 230 to be vertically inserted and to penetrate through theupper surface 220 a of the three-dimensional substrate 220 is providedon the upper surface 220 a of the substrate 220, the hollow portion 222c receiving the flange portion 230 a of the cylindrical metal case 230,which communicates with the first through-hole 222 a, is providedimmediately below the first through-hole 222 a, and the secondthrough-hole 222 e for inserting the cylindrical metal case 230therethrough and the hook portions 222 d protruding to the inside of thesecond through-hole 222 e are provided immediately below the hollowportion 222 c. Then, the top end of the cylindrical metal case 230 isinserted through the first through-hole 222 a of the substrate 220, thehollow portion 222 c of the substrate 220 receives the flange portion230 a of the cylindrical metal case 230, and the opening 230 c of thecylindrical metal case 230 engages with the hook portions 222 d, so thatthe cylindrical metal case 230 is fixed to the substrate 220. In otherwords, the cylindrical metal case 30 can be fixed by inserting it intothe first through-hole 222 a of the substrate 220, so that thecylindrical metal case 230 can be fixed without performing an insertmolding. Moreover, as the insert molding is not performed, the harnessis not required to have heat resistance for withstanding the insertmolding and it becomes possible to use a cheap harness which can be usedin many applications.

In a temperature sensor 10 according to a ninth aspect of the presentinvention, the opening 230 c of the cylindrical metal case 230 isprovided with a taper and the top end thereof is made sharp. Therefore,the opening 230 c bites into the hook portions 222 d integrally moldedwith the substrate 220 made of a resin, as a part thereof and thecylindrical metal case 230 can be firmly fixed to the substrate 220.

In a temperature sensor according to a tenth aspect of the presentinvention, the cylindrical metal case 230 can be firmly fixed to thesubstrate 220 using a pair of hook portions 222 d for sandwiching andholding the cylindrical metal case 230. In addition, a pair of hookportions is provided in a direction perpendicular to a longitudinaldirection of a groove 222 f, for receiving the harness, located on thelower surface 220 b of the substrate 220, that is, a further positionfrom a receiving position (groove) where the harness is received.Because of this, the harness does not obstruct the hook portions 222 dwhen it is installed and it is possible to easily install thecylindrical case 230 on the substrate 220.

According to an eleventh aspect of the present invention, asubstantially rod-shaped guide portion 228 vertically protruding on avertical wall of the substrate 220 is provided, the guide portion 228and the harness 240 are received in a tube 244, so that the harness 240is fixed to the guide portion 228 in a contacting state. That is, theharness 240 can be fixed to the substrate 220 without using insertmolding.

Because of this, a root portion of the harness 40 which comes out fromthe substrate 20 is unlikely to be bent due to the rigidity of the guideportion 28, and is seldom broken and disconnected. In addition, as theposition of the harness 40 with respect to the temperature sensor can bemaintained constant, the harness 40 never acts as an obstruction, and itis possible to automatically assemble the temperature sensor 10.

According to a twelfth aspect of the present invention, a rib 228 ahaving an outer diameter larger than the inner diameter of the tube 244for preventing withdrawal of the tube is preferably provided on theguide portion 228.

By this configuration, the tube 244 is made difficult to withdraw due tothe resistance of the rib 228 a. As a result, the root portion of theharness 240 which comes out from the substrate 220 is seldom broken anddisconnected, by fixing the harness 240 on the guide portion 228 usingthe tube 244.

According to a thirteenth aspect of the present invention, the guideportions 228A and 228B divided into two parts sandwich and hold theharness so that the harness 240 can be firmly fixed by the guide portion228.

According to a fourteenth aspect of the present invention, a ring-shapedgroove 224 provided on the vertical wall 220 c of the substrate 220 isadapted to receive a front end of the tube 244, so that the tube 244 isdifficult to withdraw and, as a result, the root portion of the harness240 which comes out from the substrate 220 is seldom broken anddisconnected, by fixing the harness 240 on the guide portion 228 usingthe tube 244.

The symbols in the parentheses attached to each means described aboveindicate a corresponding relationship with a specific means in theembodiments to be described later.

The present invention may be more fully understood from the descriptionof the preferred embodiments of the invention set forth below, togetherwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1A is a plan view of an evaporator temperature sensor according toa first embodiment of the present invention.

FIG. 1B is an elevation view viewed from the X1 b arrow in FIG. 1A.

FIG. 1C is an elevation view viewed from the X1 c arrow in FIG. 1A.

FIG. 1D is an elevation view viewed from the X1 d arrow in FIG. 1A.

FIG. 1E is an elevation view showing a guide portion according to avariant of the first embodiment.

FIG. 1F is an enlarged drawing in which a rib 28 a in FIG. 1D is shownin an enlarged state.

FIG. 2 is a perspective view showing important parts of an evaporatortemperature sensor according to the first embodiment of the presentinvention.

FIG. 3 is a perspective view showing the evaporator temperature sensoraccording to the first embodiment of the present invention which isinstalled on an evaporator.

FIG. 4A is a plan view of an evaporator temperature sensor according toa second embodiment of the present invention.

FIG. 4B is an elevation view viewed from the X4 b arrow in FIG. 4A.

FIG. 4C is an elevation view viewed from the X4 c arrow in FIG. 4A.

FIG. 5A is a plan view of an evaporator temperature sensor according toa third embodiment of the present invention.

FIG. 5B is an elevation view viewed from the X5 b arrow in FIG. 5A.

FIG. 5C is an elevation view viewed from the X5 c arrow in FIG. 5A.

FIG. 6A is a plan view of an evaporator temperature sensor according toa fourth embodiment of the present invention.

FIG. 6B is an elevation view viewed from the X6 b arrow in FIG. 6A.

FIG. 6C is an elevation view viewed from the X6 c arrow in FIG. 6A.

FIG. 6D is a bottom plan view of the evaporator temperature sensoraccording to the fourth embodiment.

FIG. 7A is a sectional view of an evaporator temperature sensor alongthe line X7 a–X7 a in FIG. 6B.

FIG. 7B is a sectional view showing a substrate in FIG. 7A.

FIG. 7C is a sectional view showing an aluminum case in FIG. 7A.

FIG. 7D is an enlarged drawing showing a part surrounded by a circle inFIG. 7A.

FIG. 8A is a plan view of an evaporator temperature sensor according toa first variant of a fifth embodiment of the present invention.

FIG. 8B is an elevation view viewed from the X8 b arrow in FIG. 8A.

FIG. 8C is an elevation view viewed from the X8 c arrow in FIG. 8A.

FIG. 8D is a bottom plan view of the evaporator temperature sensoraccording to the first variant of the fifth embodiment.

FIG. 9 is a perspective view showing the evaporator temperature sensoraccording to the first variant of the fifth embodiment of the presentinvention which is installed on an evaporator.

FIG. 10A is a plan view of an evaporator temperature sensor according toa first example of the first variant of the fifth embodiment of thepresent invention.

FIG. 10B is an elevation view viewed from the X10 b arrow in FIG. 10A.

FIG. 10C is an elevation view viewed from the X10 c arrow in FIG. 10A.

FIG. 10D is a bottom plan view of the evaporator temperature sensoraccording to the first example of the first variant of the fifthembodiment.

FIG. 11A is a plan view of an evaporator temperature sensor according toa second variant of the fifth embodiment of the present invention.

FIG. 11B is an elevation view viewed from the X11 b arrow in FIG. 11A.

FIG. 11C is an elevation view viewed from the X11 c arrow in FIG. 11A.

FIG. 11D is a bottom plan view of the evaporator temperature sensoraccording to the second variant of the fifth embodiment.

FIG. 12A is a plan view of an evaporator temperature sensor according toa prior art.

FIG. 12B is an elevation view viewed from the X12 b arrow in FIG. 12A.

FIG. 12C is an elevation view viewed from the X12 c arrow in FIG. 12A.

FIG. 12D is a sectional view along the line X12 d–X12 d in FIG. 12C.

FIG. 13 is a perspective view showing the evaporator temperature sensoraccording to a prior art which is installed on an evaporator.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(First Embodiment)

A first embodiment, in which a temperature sensor of the presentinvention is applied to an evaporator temperature sensor, is explainedwith reference to FIGS. 1 to 3. FIG. 1A is a plan view of an evaporatortemperature sensor according to the first embodiment of the presentinvention, FIG. 1B is an elevation view from the arrow X1 b in FIG. 1A,FIG. 1C is an elevation view from the arrow X1 c in FIG. 1A, and FIG. 1Dis an elevation view from the arrow X1 d in FIG. 1A.

An evaporator temperature sensor 10, as shown in FIG. 1B, comprises: athree-dimensional substrate 20 including an upper surface 20 a, a lowersurface 20 b and a vertical wall 20 c; an installation portion 26 forinstalling the evaporator temperature sensor on an evaporator 50 whichvertically stands on the upper surface 20 a of the substrate 20; and acylindrical portion 30 which vertically stands on the upper surface 20 aof the substrate 20. The substrate 20 has a form in which two, large andsmall, rectangular prisms, of which the surfaces are suitably finishedrespectively, are connected to each other, as shown in FIG. 1A. Thecylindrical portion 30 comprises an aluminum case.

The installation portion 26 has a sharp top end and is provided withreturn edges 26 a acting as hooks on the side surfaces thereof (refer toFIG. 1D). The cylindrical portion 30 is formed in an cylindrical shapehaving a sharp top end, on an upper surface of a cylindrical boss 34having a circular columnar shape vertically protruding on the uppersurface 20 a of the substrate 20. A temperature sensing element 32 isaccommodated near the top end of the cylindrical portion 30. A harness40 extending from the temperature sensing element 32 comes out from thevertical wall 20 c of the substrate 20 after passing through the insideof the cylindrical portion 30.

A substantially rod-shaped guide portion 28 which vertically protrudesfrom the vertical wall 20 c is provided along the harness 40. The guideportion 28 comprises: a first taper portion 28 b which has an uppertaper surface and side taper surfaces tapering from the vertical wall 20c; an extending portion 28 c extending in the diameter same as that ofthe front end of the first taper portion 28 b; a rib 28 a having adiameter larger than that formed on the front end of the extendingportion 28 c; a second taper portion 28 d which has an upper tapersurface and side taper surfaces tapering from the front end of the rib28 a; and a front end 28 e which is a vertical surface provided on thefront end of the second taper portion 28 d. In this embodiment, theguide portion 28 has a flat bottom surface as shown in FIG. 1D, but theguide portion 28 may be provided with a recess 28 f for receiving theharness 40 on the bottom surface of the guide portion 28, as in avariant example shown in FIG. 1E. The substrate 20, the installationportion 26, the cylindrical portion 30, the cylindrical boss 34 and theguide portion 28, described above, are integrally formed with a resin byinsert molding and then the cylindrical portion 30 comprising analuminum case is installed on the substrate 20 in a standing state.

The guide portion 28 and the harness 40 are accommodated in an end of avinyl tube 44 for protecting the harness. The state of the vinyl tube 44in which the guide portion 28 is not accommodated yet is shown in FIG. 2(viewed from the X2 arrow direction in FIG. 1B). The harness 40 is fixedto the guide portion 28 by accommodating them in the vinyl tube 44 sothat the harness 40 comes into contact with the guide portion 28.

The rib 28 a in FIG. 1D is shown in FIG. 1F as an enlarged view. Thesize of the rib 28 a is decided and acts as a stopper for preventing thewithdrawal of the vinyl tube 44. In other words, if the semi-circularouter periphery without a bottom surface of the rib 28 a is D1, thedistance from the edge P2 of the rib 28 a to the intersecting point P3of the tangent line with the left harness 40 in the figure from the edgeP2 is D2, the outer peripheral distance of the left harness 40 from thepoint P3 to the intersecting point P4 of the tangent line between theleft harness and the right harness in the figure is D3, the distancebetween the intersecting points P4 and p5 of the tangent line betweenthe left harness and the right harness in the figure is D4, the outerperipheral distance of the right harness 40 from the point P5 to theintersecting point P6 of the tangent line from the edge P1 of the rib 28a is D5, and the distance from the intersecting point P6 of the tangentline to the edge P1 of the rib 28 a is D6, the rib 28 a is formed sothat D1+D2+D3+D4+D5+D6 is larger than the inner diameter of the vinyltube 44. The first taper portion 28 b of the guide portion 28 has afront end the diameter of which is smaller than the outer diameter ofthe rib 28 a and has a root end the diameter of which is larger than theouter diameter of the rib 28 a, as shown in FIG. 1B.

The installation operation of the evaporator temperature sensor 10 ofthe first embodiment to the evaporator 50 will be described below withreference to FIG. 3.

The evaporator temperature sensor 10 is installed by inserting theinstallation portion 26 and the cylindrical portion 30 into spacesbetween the fins 52 of the evaporator 50 in a predetermined position andthe evaporator 50 is accommodated in the air-conditioner case 60. As theevaporator temperature sensor 10 is installed in a predeterminedposition, the vinyl tube 44 accommodating the harness is received in thegroove 64. Then, the operation is completed by closing the lids 62A and62B. In the first embodiment, the position of the vinyl tube 44 (harness40) is decided by deciding the position of the evaporator temperaturesensor 10 and, therefore, the assembling of the evaporator temperaturesensor 10 into the air-conditioner case 60 can be automatically carriedout.

In the evaporator temperature sensor 10 of the first embodiment, theguide portion 28 with a substantially rod-like shape, which protrudesvertically, is provided on the vertical wall 20 c of the substrate 20and the guide portion 28 and the harness 40 are accommodated in thevinyl tube 44, so that the harness 40 comes into contact with and isfixed on the guide portion 28 of the harness 40. Therefore, the rootportion of the harness 40 at which the harness 40 comes out from thesubstrate 20 becomes difficult to bend due to the rigidity of the guideportion 28 and the harness 40 is seldom broken and disconnected due tothe vibration of an engine, a compressor of an air-conditioner, or thelike. In addition, as the position of the harness 40 with respect to theevaporator temperature sensor 10 is kept constant, the harness 40 doesnot act as an obstruction and the assembling of the evaporatortemperature sensor 10 can be automatically carried out. In the firstembodiment, as the installation portion 26 comprises return edges 26 aacting as hooks for preventing the withdrawal thereof, the return edge26 a is engaged with the cooling fins by inserting the installationportion 26 into a space between the cooling fins of the evaporator andthe evaporator temperature sensor 10 can be easily installed between thecooling fins 52 of the evaporator 50.

The rib 28 a which has an outer diameter larger than an inner diameterof the vinyl tube 44 is provided in the guide portion 28, so that thevinyl tube 44 is hard to withdraw due to the resistance of the rib 28 a.As the harness 40 is fixed to the guide portion 28 using the vinyl tube44, the root portion of the harness 40 at which the harness 40 comes outfrom the substrate 20 is seldom broken and disconnected.

The position where the evaporator temperature sensor is installed on theevaporator differs according to the type of the evaporator, the shape ofthe air-conditioner case, etc. In the evaporator temperature sensor 10of the first embodiment, however, as it is possible to install it atvarious positions by changing the length of the vinyl tube 44, theevaporator temperature sensor 10 can be used in many applications.

(Second Embodiment)

The evaporator temperature sensor 10 according to a second embodiment ofthe present invention will be described below with reference to FIG. 4.FIG. 4A is a plan view of the evaporator temperature sensor according tothe second embodiment, FIG. 4B is an elevation view from the X4 b arrowin FIG. 4A, and FIG. 4C is an elevation view from the X4 c arrow in FIG.4A.

The evaporator temperature sensor 10 of the second embodiment is thesame as that of the first embodiment except the construction of theguide portion 28 and, therefore, only the guide portion 28 is explainedherein. In the first embodiment, the guide portion 28 is formed in arod-like shape but in the second embodiment, as shown in FIG. 4A, theguide portion 28 comprises two rod-like guide members 28A and 28B andhas a construction in which the harness 40 is sandwiched between theguide members 28A and 28B and is supported thereby.

The guide member 28B at one side of the harness 40, as shown in FIG. 4B,comprises: a first taper portion 28 b which has an upper taper surface,a lower taper surface and side taper surfaces tapering from a verticalwall 20 c; an extending portion 28 c extending in the diameter the sameas that of the front end of the first taper portion 28 b; a rib 28 ahaving an outer diameter larger than that formed on the front end of theextending portion 28 c; a second taper portion 28 d which has side tapersurfaces tapering from the front end of the rib 28 a; and a front end 28e which is a vertical surface provided on the front end of the secondtaper portion 28 d. The sizes of the rib 28 a and the first taperportion 28 b are decided to act as a stopper for preventing thewithdrawal of the vinyl tube 44 as in the first embodiment.

According to the evaporator temperature sensor 10 of the secondembodiment, as the harness 40 is sandwiched between and is supported bythe guide members 28A and 28B, the guide portion 28 can fix the harness40 more firmly.

(Third Embodiment)

An evaporator temperature sensor 10 according to a third embodiment ofthe present invention will be described below with reference to FIGS. 5Ato 5C. FIG. 5A is a plan view of the evaporator temperature sensoraccording to the third embodiment, FIG. 5B is an elevation view from theX5 b arrow in FIG. 5A, and FIG. 5C is an elevation view from the X5 carrow in FIG. 5A.

The evaporator temperature sensor 10 of the third embodiment comprises aring-like groove 24 for receiving the front end of the vinyl tube 44 ina vertical wall 20 c of the substrate 20. The other construction of theevaporator temperature sensor 10 of the third embodiment is the same asthat of the first embodiment.

In the third embodiment, the top end of the vinyl tube 44 is received inthe ring-like groove 24 of the vertical wall 20 c of the substrate 20,so that the vinyl tube 44 is hard to withdraw. As the harness 40 isfixed to the guide portion 28 using the vinyl tube 44, the root portionof the harness 40 at which the harness 40 comes out from the substrate20 is not broken and disconnected.

In the third embodiment, the guide portion 28 has the same constructionas that of the first embodiment, but the groove of the third embodimentmay, of course, be applied to the construction of the guide portion 28of the second embodiment.

(Fourth Embodiment)

A fourth embodiment in which a temperature sensor of the presentinvention is applied to an evaporator temperature sensor will bedescribed below with reference to FIGS. 6A to 6D and FIGS. 7A to 7D.

FIG. 6A is a plan view of the evaporator temperature sensor according tothe fourth embodiment of the present invention, FIG. 6B is an elevationview from the X6 b arrow in FIG. 6A, FIG. 6C is an elevation view fromthe X6 c arrow in FIG. 6A and FIG. 6D is an bottom plan view thereof.

An evaporator temperature sensor 210, as shown in FIG. 6B, comprises: asubstantially cubic substrate 220 including an upper surface 220 a, alower surface 220 b and a vertical wall 220 c; an installation portion226 for installing on an evaporator 250 which vertically stands on theupper surface 220 a of the substrate 220; and an aluminum case 230 whichvertically stands on the upper surface 220 a of the substrate 220. Theinstallation portion 226 is sharp at its top end and is provided withreturn edges 226 a on its side surfaces (refer to FIG. 6C).

FIG. 7A is a sectional view along the line X7 a–X7 a of the evaporatortemperature sensor 210 shown in FIG. 6B, FIG. 7B is a sectional viewshowing the substrate 220 in FIG. 7A, FIG. 7C is a sectional viewshowing the aluminum case 230 in FIG. 7A, and FIG. 7D is an enlargedview of the portion surrounded by a circular line in FIG. 7A. Thealuminum case 230, as shown in FIG. 7C, is formed in a bag-like shapehaving an opening 230 c at its lower end, has a flange portion 230 ahaving a diameter larger than the top end side thereof, on the upperportion of the opening 230 c, and has a step portion 230 b having acrank-like section at the upper side of the flange portion 230 a. Atemperature sensing element 232 is installed near the top end of thealuminum case 230 and is connected to the exterior from the opening 230c via a signal wire 242 and a harness 240. Fillers 236 are filled in thealuminum case 230.

The substrate 220, as shown in FIG. 7B, is provided with a firstthrough-hole 222 a, through which the aluminum case 230 penetratesvertically with respect to an upper surface 220 a of the substrate 220,on the upper surface 220 a thereof. The substrate 220 is also providedwith a hollow portion 222 c, for receiving the flange portion 230 a ofthe aluminum case 230, which communicates with the first through-hole222 a immediately above. The hollow portion 222 c is a cylindrical spacecorresponding to the flange portion 230 a and comprises a right wall 222cw and an end contacting portion 222 cc including a flat surface cominginto contact with the step portion 230 b. Immediately below the hollowportion 222 c, a second through-hole 222 e for the aluminum case 230 topenetrate therethrough and hook portions 222 d having a hook-like shapeand protruding to the inside of the second through-hole 222 e areprovided. A pair of the hook portions 222 d is provided so that theyextend in a direction toward the center of the second through-hole 222e, as shown in FIG. 6D. In the fourth embodiment, a pair of the hookportions is provided, but the number of the hook portions may be one ormore than three.

A groove portion 222 f for receiving the harness 240 is formed on alower surface 222 b of the substrate 220 along the longitudinaldirection of the substrate 220, as shown FIGS. 6D and 6C.

In installing an aluminum case 230 shown in FIG. 7C into the substrate220 shown in FIG. 7B, the top end of the aluminum case 230 is penetratedthrough the first through-hole 222 a of the substrate 220, the flangeportion 230 a of the aluminum case 230 is received in the hollow portion222 c of the substrate 220 and the step portion 230 b is come intocontact with the end contacting portion 222 cc, so that the position ofthe aluminum case 230 is fixed. In this condition, the opening 230 c ofthe aluminum case 230 is engaged with the hook portions 222 d in orderto fix the aluminum case 230 in the substrate 220. In other words, asthe aluminum case 230 can be fixed by being inserted into the firstthrough-hole 222 a of the substrate 220, the aluminum case 230 can befixed into the substrate 220 without using the insert molding. Further,as the insert molding is not carried out, the harness is not required tohave a heat resistance capable of enduring the insert molding, so that aharness which is used in many applications, and is not expensive, can beused.

In addition, in order not to use the insert molding, an aluminum case230 attached with a harness 240 with various lengths can be easilyassembled with the substrate 220. Due to this, an aluminum case 230comprising a harness 240 with various lengths, especially with a longlength, can also be automatically assembled with the substrate 220.

As shown in FIG. 7D which is an enlarged view of a part surrounded by acircle in FIG. 7A, the opening 230 c of the aluminum case 230 is taperedand is sharp at its top end. Therefore, the opening 230 c bites into thehook portions 222 d integrally formed with the substrate 220, as a partthereof, using a resin and can fix the aluminum case 230 on thesubstrate 220 at retaining strength of the similar level as that of theinsert molding.

In a fourth embodiment, as shown in FIG. 6D, as the aluminum case 230 issandwiched and supported by a pair of hook portions 222 d, the aluminumcase 230 can be firmly fixed to the substrate 220. Moreover, the hookportions 222 d are provided on positions in the longitudinal directionand the perpendicular direction of the groove 222 f, for receiving theharness 240, located in the lower surface 220 b of the substrate 220,i.e. the further positions from the received position (groove) of theharness 240. Therefore, the harness 240 hardly obstructs the hookportions 222 d during installation, so that the aluminum case 230 can beeasily installed on the substrate 220.

In the evaporator temperature sensor 210 of the fourth embodiment, asaluminum which is a good conductor of heat, is used for the aluminumcase 230, the temperature of the evaporator 250 can be transferred tothe temperature sensing element 232 in a short time.

(Fifth Embodiment)

An evaporator temperature sensor 210 according to a fifth embodiment ofthe present invention will be described below with reference to FIGS. 8Ato 8D and FIG. 9.

FIG. 8A is a plan view of the evaporator temperature sensor according tothe fifth embodiment of the present invention, FIG. 8B is an elevationview from the X8 b arrow in FIG. 8A, FIG. 8C is an elevation view fromthe X8 c arrow in FIG. 8A and FIG. 8D is a bottom plan view thereof.

An evaporator temperature sensor 210 of the fifth embodiment is similarto that of the fourth embodiment described above with reference to FIGS.6A to 6D and FIGS. 7A to 7D. However, in the fifth embodiment, asubstantially rod-shaped guide portion 228 is provided which protrudesperpendicularly on a vertical wall 220 c along a harness 240. A rib 228a having an outer diameter larger than the inner diameter of a vinyltube 244 is provided at a substantially center position of the guideportion 228.

The guide portion 228 and the harness 240 are accommodated in the end ofthe vinyl tube 244 for protecting the harness. In this configuration,the harness 240 is fixed to the guide portion 228 in a contacting stateby being accommodated in the vinyl tube 244. The size of the rib 228 ais determined so as to act as a stopper of the vinyl tube 244 forpreventing the withdrawal thereof.

The installation operation of the evaporator temperature sensor 210 ofthe fifth embodiment to the evaporator 250 will be described below withreference to FIG. 9.

The evaporator temperature sensor 210 is installed by inserting theinstallation portion 226 and the aluminum case 230 into spaces betweenthe fins 252 of the evaporator 250 in predetermined positions and theevaporator 250 is accommodated in the air-conditioner case 260. As theevaporator temperature sensor 210 is installed in a predeterminedposition, the vinyl tube 244 accommodating the harness is received in agroove 264. Then, the operation is completed by closing lids 262A and262B. In the fifth embodiment, the position of the vinyl tube 244(harness) is decided by deciding the position of the evaporatortemperature sensor 210 and, therefore, the assembling of the evaporatortemperature sensor 210 into the air-conditioner case 260 can beautomatically carried out.

In the evaporator temperature sensor 210 of the fifth embodiment, theguide portion 228 with a substantially rod-like shape, which protrudesvertically, is provided on the vertical wall 220 c of the substrate 220and the guide portion 228 and the harness 240 are accommodated in thevinyl tube 244, so that the harness 240 comes into contact with and isfixed on the guide portion 228.

In other words, the harness 240 can be fixed on the substrate 220 byassembling and is not fixed by the insert molding. Therefore, the rootportion of the harness 240 at which the harness 240 comes out from thesubstrate 220 becomes difficult to bend due to the rigidity of the guideportion 228 and is seldom broken and disconnected due to the vibrationof an engine, a compressor of an air-conditioner, or the like. Inaddition, as the position of the harness 240 with respect to theevaporator temperature sensor 210 is kept constant, the harness 240 doesnot act as an obstruction and the assembling of the evaporatortemperature sensor 210 can be automatically carried out. In the fifthembodiment, as the installation portion 226 has return edges 226 a forpreventing withdrawal, the return edge 226 a is engaged by inserting theinstallation portion 226 into a space between the cooling fins of theevaporator and the evaporator temperature sensor 210 can be easilyinstalled onto the cooling fins 252 of the evaporator 250.

The rib 228 a which has an outer diameter larger than an inner diameterof the vinyl tube 244 is provided in the guide portion 228, so that thevinyl tube 244 is hard to withdraw due to the resistance of the rib 228a. As the harness 240 is fixed to the guide portion 228 using the vinyltube 244, the root portion of the harness 240 at which the harness 240comes out from the substrate 220 is not broken and disconnected.

The position where the evaporator temperature sensor is installed on theevaporator differs according to the type of the evaporator, the shape ofthe air-conditioner case, etc. In the evaporator temperature sensor 210of the fifth embodiment, however, as it is possible to install it atvarious positions by changing the length of the vinyl tube 244, theevaporator temperature sensor 210 can be used in many applications.

(First Variant of the Fifth Embodiment)

An evaporator temperature sensor 210 according to a first variant of thefifth embodiment will be described below with reference to FIGS. 10A to10D and FIG. 9.

FIG. 10A is a plan view of the evaporator temperature sensor accordingto the first variant of the fifth embodiment, FIG. 10B is an elevationview from the X10 b arrow in FIG. 10A, FIG. 10C is an elevation viewfrom the X10 c arrow in FIG. 10A and FIG. 10D is a bottom plan viewthereof.

An evaporator temperature sensor 210 of the first variant of the fifthembodiment is similar to that of the fifth embodiment except theconstruction of the guide portion 228, so that only the guide portion228 is explained. Though, in the fifth embodiment, the guide portion 228is formed in a rod-like shape, in the first variant of the fifthembodiment, as shown in FIG. 10A, the guide portion 228 is formed by tworod-shaped guide members 228A and 228B, and the harness 240 issandwiched and is supported between the guide members 228A and 228B.

In the guide member 228B at one side, a rib 228 a having an outerdiameter larger than that of the guide member 228B is provided at asubstantially center position of the guide portion 228, as shown in FIG.10B.

In the evaporator temperature sensor 210 of the first variant of thefifth embodiment, as the harness 240 is sandwiched and supported by theguide members 228A and 228B, the harness 240 can be more firmly fixed bythe guide portion 228.

(Second Variant of the Fifth Embodiment)

An evaporator temperature sensor 210 according to a second variant ofthe fifth embodiment will be described below with reference to FIGS. 11Ato 11D.

FIG. 11A is a plan view of the evaporator temperature sensor accordingto the second variant of the fifth embodiment, FIG. 11B is an elevationview from the X11 b arrow in FIG. 11A, FIG. 11C is an elevation viewfrom the X11 c arrow in FIG. 11A, and FIG. 11D is a bottom plan viewthereof.

In an evaporator temperature sensor 210 of the second variant of thefifth embodiment, a ring-like groove 224 for receiving the front end ofthe vinyl tube 244 is formed in the vertical wall 220 c of the substrate220. The rest of the construction thereof is similar to that of thefifth embodiment.

In the second variant of the fifth embodiment, a ring-like groove 224 inthe vertical wall 220 c of the substrate 220 receives the front end ofthe vinyl tube 244, so that the vinyl tube 244 is hard to withdraw. Asthe harness 240 is fixed to the guide portion 228 using the vinyl tube244, the root portion of the harness 240 at which the harness 240 comesout from the substrate 220 is not broken and disconnected. In the secondvariant of the fifth embodiment, though the guide portion 228 has aconstruction similar to that of the fifth embodiment, it is, of course,possible to apply the groove of the second variant of the fifthembodiment to the construction of the guide portion 228 of the firstvariant of the fifth embodiment.

APPLICABILITY IN INDUSTRY

In the embodiments described above, the examples in which thetemperature sensor of the present invention is applied to the evaporatortemperature sensor is shown, but it is possible to apply the temperaturesensor of the present invention to a temperature sensor for a radiatorand further, it can be applied to various sensors. Moreover, it is noneed to say that, in the embodiments described above, an example inwhich an aluminum case is used as a cylindrical metal case is describedbut a cylindrical metal case made of, for example, copper, stainlesssteel, or the like can have the construction of the present inventionwhen they are assembled.

While the invention has been described by reference to specificembodiments chosen for the purposes of illustration, it should beapparent that numerous modifications could be made thereto by thoseskilled in the art without departing from the basic concept and scope ofthe invention.

1. A sensor comprising: a sensing element which is received near a topend of a cylindrical vertically portion mounted on a substrate in astanding state; a harness extending from the sensing element which comesout from the a vertical wall of the substrate; a guide portion extendingfrom the vertical wall of the substrate along the harness, wherein theharness comes into contact with and is fixed to the guide portion byaccommodating the guide portion and the harness in a tube which retainsthe harness; and a ring-shaped groove provided on a vertical wall of thesubstrate, wherein the ring-shaped groove accommodates a front end ofthe tube.
 2. A temperature sensor comprising: a three-dimensionalsubstrate made of a resin and including an upper surface, a lowersurface, a vertical wall and a substantially rod-shaped guide portionvertically protruding on the vertical wall; an installation portion forinstalling on a measured member and vertically mounted on the uppersurface of the substrate in a standing state; a cylindrical portionreceiving a temperature sensing element near a top end thereof andvertically mounted on the upper surface of the substrate in a standingstate; a harness connected to the temperature sensing element and comingout from the vertical wall of the substrate alter passing through aninside of the cylindrical portion; and a tube for fixing the harness tothe guide portion in a contacting state by accommodating the guideportion and the harness.
 3. The temperature sensor as set forth in claim2, wherein a rib for preventing the withdrawal of the tube is providedon the guide portion.
 4. The temperature sensor as set forth in claim 2,wherein the guide portion is divided into two parts and the harness isprovided in a center space between the two parts.
 5. The temperaturesensor as set forth in claim 2, wherein a ring-shaped groove is providedon the vertical wall of the substrate and is made to accommodate a frontend of the tube.
 6. The temperature sensor as set forth in claim 2,wherein the installation portion comprises return edges for preventingthe withdrawal of the installation portion from cooling fins of anevaporator.